JCB 1CX Series 1 and Series 2 Backhoe Loader Service Repair Manual Instant Download

1
Service Manual

1CX
Service Manual - 1CX
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Maintenance
Section A - Attachments
Section B - Body and Framework
Section C - Electrics
Section E - Hydraulics
Section F - Transmission
Section G - Brakes
Section J - Tracks
Section K - Engine

Publication No. 9803/9960-4
World Class Customer Support
Copyright 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel [phone] Fax [phone]
2
Section 1
General Information
Service Manual - 1CX
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Maintenance
Section A - Attachments
Section B - Body and Framework
Section C - Electrics
Section E - Hydraulics
Section F - Transmission
Section G - Brakes
Section J - Tracks
Section K - Engine

Publication No. 9803/9960-3
World Class Customer Support
Copyright 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
Issued by JCB Technical Publications, JCB
Aftermarket Training, Woodseat, Rocester,
Staffordshire, ST14 5BW, England. Tel 44 1889
591300 Fax [phone]
3
Section 1 - General Information Contents Content
s Page No. Introduction About This Manual
..................................................
................................... 1-1 Machine
Model and Serial Number ..........................
.............................1-1 Using the
Service Manual ...................................
..................................1-1 Section
Numbering ........................................
........................................1-1 Cab/Ca
nopy .............................................
.............................................1-1 L
eft Side, Right Side .............................
.................................................1
-1 Identifying Your Machine ......................
..................................................
... 1-3 Machine Identification Plate
..................................................
................1-3 Component Identification
Plates ...........................................
.................1-4 Typical Engine
Identification Number ............................
........................1-5 Torque Settings Zinc
Plated Fasteners and Dacromet Fasteners
....................................... 1-7
Introduction .....................................
..................................................
.....1-7 Bolts and Screws ........................
..................................................
.........1-7 Hydraulic Connections
..................................................
........................... 1-11 'O' Ring Face
Seal System ......................................
............................ 1-11 'Torque Stop'
Hose System ......................................
...........................1-14 Service
Tools Numerical List Section B - Body and
Framework ....................................
1-15 Tool Detail Reference Section B - Body and
Framework ........................ 1-16
Numerical List Section C - Electrics
..................................................
...... 1-20 Tool Detail Reference Section C -
Electrics ........................................
..... 1-21 Numerical List Section E- Hydraulics
..................................................
.... 1-22 Tool Detail Reference Section E-
Hydraulics .......................................
.... 1-25 Service Consumables Sealing and
Retaining Compounds ..............................
........................... 1-29 Terms and
Definitions Colour Coding ........................
..................................................
................ 1-31 Hydraulic Schematic Colour
Codes ............................................
.........1-31
1-i
1-i
4
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Section 1 - General Information Introduction Abo
ut This Manual
Machine Model and Serial Number This manual
provides information for the following model(s)
in the JCB machine range
Finally, please remember above all else safety
must come first!
Section Numbering
T11-005 The manual is compiled in sections, the
first three are numbered and contain information
as follows

• 1CX (series 1) from 751600
• 1CX (series 2) from 1743153

Using the Service Manual

1. General Information - includes torque settings
   and service tools.
2. Care and Safety - includes warnings and cautions
   pertinent to aspects of workshop procedures etc.
3. Maintenance - includes service schedules and
   recommended lubricants for all the machine.

T11-004 This publication is designed for the
benefit of JCB Distributor Service Engineers who
are receiving, or have received, training by JCB
Technical Training Department.
These personnel should have a sound knowledge of
workshop practice, safety procedures, and general
techniques associated with the maintenance and
repair of hydraulic earthmoving equipment.
The remaining sections are alphabetically coded
and deal with Dismantling, Overhaul etc. of
specific components, for example
The illustrations in this publication are for
guidance only. Where the machines differ, the
text and/or the illustration will specify.

1. Attachments
2. Body and Framework, etc.

General warnings in Section 2 are repeated
throughout the manual, as well as specific
warnings. Read all safety statements regularly,
so you do not forget them.
Section contents, technical data, circuit
descriptions, operation descriptions etc. are
inserted at the beginning of each alphabetically
coded section.
Renewal of oil seals, gaskets, etc., and any
component showing obvious signs of wear or
damage is expected as a matter of course. It is
expected that components will be cleaned and
lubricated where appropriate, and that any
opened hose or pipe connections will be blanked
to prevent excessive loss of hydraulic fluid and
ingress of dirt.
Cab/Canopy
T1-003_2 This manual frequently makes references
to the cab. For instance, 'do not operate the
machine without a manual in the cab'. It should
be noted that these statements also apply to
canopy build machines.
Where a torque setting is given as a single
figure it may be varied by plus or minus 3.
Torque figures indicated are for dry threads,
hence for lubricated threads may be reduced by
one third.
Left Side, Right Side
P2-1002 In this manual, 'left' A and 'right' B
mean your left and right when you are seated
correctly in the machine.
The manufacturer's policy is one of continuous
improvement. The right to change the
specification of the machine without notice is
reserved. No responsibility will be accepted for
discrepancies which may occur between
specifications of the machine and the
descriptions contained in this publication.
This is so whether you are facing the loader
(front) or the backhoe (rear).
1-1
6
Section 1 - General Information Introduction About
This Manual
A B A
B
C003690
Fig 1.
1-1
7
Section 1 - General Information Introduction Ident
ifying Your Machine Identifying Your
Machine Machine Identification Plate Your
machine has an identification plate mounted as
shown. K Fig 2. ( 1-3). The serial numbers of the
machine and its major units are stamped on the
plate. Note The machine model and build
specification is indicated by the VIN (earlier
machines) or PIN (later machines). A detailed
description of the VIN/PIN numbering system is
included later in this section. The serial
number of each major unit is also stamped on the
unit itself. If a major unit is replaced by a new
one, the serial number on the identification
plate will be wrong. Either stamp the new number
of the unit on the identification plate, or
simply stamp out the old number. This will
prevent the wrong unit number being quoted when
replacement parts are ordered. The machine and
engine serial numbers can help identify exactly
the type of equipment you have.
S203651
Fig 2.
1-1
8
Section 1 - General Information Introduction
Identifying Your Machine Typical Product
Identification Number (PIN)
Component Identification Plates
Typical Vehicle Identification Number (VIN) 1 2 3 4
JCB 1CXWS L 01299167
1 2 3 4 5 6 7
SLP 1CX S B 6 E 751601 1 World Manufacturer Identification (3 Digits).
JCB UK Build.
1 World Manufacturer Identification.
2 Machine Type and Model (5 Digits).
2 Machine Model.
1CXWS 1CX Wheeled Standard.
3 Steer Type (S Standard, H High Flow).
3 Check Letter (1 Digit).
4 Build Type (A Canopy, B Cab).
The check letter is used to verify the
authenticity of a machine's PIN.
5 Year of Manufacture
2 2002
4 Machine Serial Number (8 Digits).
3 2003
Each machine has a unique serial number.

• 4 2004
• 5 2005
• 6 2006
• 7 2007
• Manufacturer Location (E England).
• Machine Serial Number.

1-1
9
Section 1 - General Information Introduction Ident
ifying Your Machine Typical Engine Identification
Number The engine data label is located on the
cylinder block at position A. K Fig 3. ( 1-5).
The data label includes the engine
identification number. A typical engine
identification number is explained as follows
RE 50261 U 500405 P
1 2 3 4 5

• Engine Type
• GN Naturally aspirated (Tier 3). GP
  Turbocharged (Tier 3).
• HP Naturally aspirated (Tier 2). RG
  Turbocharged (Tier 2).
• Build Number
• Country of manufacture U United Kingdom
• Engine Serial Number
• Year of Manufacture

T017650-1
Fig 3.
1-1
10
Section 1 - General Information Torque
Settings Zinc Plated Fasteners and Dacromet
Fasteners Torque Settings Zinc Plated Fasteners
and Dacromet Fasteners T11-002
Introduction
Bolts and Screws
Some external fasteners on JCB machines are
manufactured using an improved type of corrosion
resistant finish. This type of finish is called
Dacromet and replaces the original Zinc and
Yellow Plating used on earlier machines.
Use the following torque setting tables only
where no torque setting is specified in the text.
Note Dacromet fasteners are lubricated as part
of the plating process, do not lubricate.
The two types of fasteners can be readily
identified by colour and part number suffix. K
Table 1. Fastener Types ( 1-7).
Torque settings are given for the following
conditions
Condition 1

• Un-lubricated fasteners
• Zinc fasteners
• Yellow plated fasteners

Table 1. Fastener Types
Fastener Type Colour Part No. Suffix
Zinc and Yellow Golden finish 'Z' (e.g. 1315/3712Z)
Dacromet Mottled silver finish 'D' (e.g. 1315/3712D)
Condition 2

• Zinc flake (Dacromet) fasteners
• Lubricated zinc and yellow plated fasteners
• Where there is a natural lubrication. For
  example, cast iron components

Note As the Dacromet fasteners have a lower
torque setting than the Zinc and Yellow
fasteners, the torque figures used must be
relevant to the type of fastener.
Note A Dacromet bolt should not be used in
conjunction with a Zinc or Yellow plated nut, as
this could change the torque characteristics of
the torque setting further. For the same reason,
a Dacromet nut should not be used with a Zinc or
Yellow plated bolt.
Verbus Ripp Bolts
Note All bolts used on JCB machines are high
tensile and must not be replaced by bolts of a
lesser tensile specification.
Fig 1.
Note Dacromet bolts, due to their high corrosion
resistance are used in areas where rust could
occur. Dacromet bolts are only used for external
applications. They are not used in applications
such as gearbox or engine joint seams or
internal applications.
Torque settings for these bolts are determined by
the application. Refer to the relevant procedure
for the required settings.
1-7
1-10
11
Section 1 - General Information Torque
Settings Zinc Plated Fasteners and Dacromet
Fasteners Table 2. Torque Settings - UNF Grade
'S' Fasteners
Bolt Size Bolt Size Hexagon (A/F) Condition 1 Condition 1 Condition 1 Condition 2 Condition 2 Condition 2
in. mm in. Nm kgf m lbf ft Nm kgf m lbf ft
1/4 6.3 7/16 11.2 1.1 8.3 10.0 1.0 7.4
5/16 7.9 1/2 22.3 2.3 16.4 20.0 2.0 14.7
3/8 9.5 9/16 40.0 4.1 29.5 36.0 3.7 26.5
7/16 11.1 5/8 64.0 6.5 47.2 57.0 5.8 42.0
1/2 12.7 3/4 98.00 10.0 72.3 88.0 9.0 64.9
9/16 14.3 13/16 140.0 14.3 103.2 126.0 12.8 92.9
5/8 15.9 15/16 196.0 20.0 144.6 177.0 18.0 130.5
3/4 19.0 1 1/8 343.0 35.0 253.0 309.0 31.5 227.9
7/8 22.2 1 15/16 547.0 55.8 403.4 492.0 50.2 362.9
1 25.4 1 1/2 814.0 83.0 600.4 732.0 74.6 539.9
1 1/8 31.7 1 7/8 1181.0 120.4 871.1 1063.0 108.4 784.0
1 1/4 38.1 2 1/4 1646.0 167.8 1214.0 1481.0 151.0 1092.3
Table 3. Torque Settings - Metric Grade 8.8
Fasteners
Bolt Size Bolt Size Hexagon (A/F) Condition 1 Condition 1 Condition 1 Condition 2 Condition 2 Condition 2
ISO Metric Thread mm mm Nm kgf m lbf ft Nm kgf m lbf ft
M5 5 8 5.8 0.6 4.3 5.2 0.5 3.8
M6 6 10 9.9 1.0 7.3 9.0 0.9 6.6
M8 8 13 24.0 2.4 17.7 22.0 2.2 16.2
M10 10 17 47.0 4.8 34.7 43.0 4.4 31.7
M12 12 19 83.0 8.5 61.2 74.0 7.5 54.6
M16 16 24 205.0 20.9 151.2 184.0 18.8 135.7
M20 20 30 400.0 40.8 295.0 360.0 36.7 265.5
M24 24 36 690.0 70.4 508.9 621.0 63.3 458.0
M30 30 46 1372.0 139.9 1011.9 1235.0 125.9 910.9
M36 36 55 2399.0 244.6 1769.4 2159.0 220.0 1592.4
1-8
1-10
12
Section 1 - General Information Torque
Settings Zinc Plated Fasteners and Dacromet
Fasteners Table 4. Metric Grade 10.9 Fasteners
Bolt Size Bolt Size Hexagon (A/F) Condition 1 Condition 1 Condition 1 Condition 2 Condition 2 Condition 2
ISO Metric Thread mm mm Nm kgf m lbf ft Nm kgf m lbf ft
M5 5 8 8.1 0.8 6.0 7.3 0.7 5.4
M6 6 10 13.9 1.4 10.2 12.5 1.3 9.2
M8 8 13 34.0 3.5 25.0 30.0 3.0 22.1
M10 10 17 67.0 6.8 49.4 60.0 6.1 44.2
M12 12 19 116.0 11.8 85.5 104.0 10.6 76.7
M16 16 24 288.0 29.4 212.4 259.0 26.4 191.0
M20 20 30 562.0 57.3 414.5 506.0 51.6 373.2
M24 24 36 971.0 99.0 716.9 874.0 89.1 644.6
M30 30 46 1930.0 196.8 1423.5 1737.0 177.1 1281.1
M36 36 55 3374.0 344.0 2488.5 3036.0 309.6 2239.2
Table 5. Metric Grade 12.9 Fasteners
Bolt Size Bolt Size Hexagon (A/F) Condition 1 Condition 1 Condition 1 Condition 2 Condition 2 Condition 2
ISO Metric Thread mm mm Nm kgf m lbf ft Nm kgf m lbf ft
M5 5 8 9.8 1.0 7.2 8.8 0.9 6.5
M6 6 10 16.6 1.7 12.2 15.0 1.5 11.1
M8 8 13 40.0 4.1 29.5 36.0 3.7 26.5
M10 10 17 80.0 8.1 59.0 72.0 7.3 53.1
M12 12 19 139.0 14.2 102.5 125.0 12.7 92.2
M16 16 24 345.0 35.2 254.4 311.0 31.7 229.4
M20 20 30 674.0 68.7 497.1 607.0 61.9 447.7
M24 24 36 1165.0 118.8 859.2 1048.0 106.9 773.0
M30 30 46 2316.0 236.2 1708.2 2084.0 212.5 1537.1
M36 36 55 4049.0 412.9 2986.4 3644.0 371.6 2687.7
1-9
1-10
13
Section 1 - General Information Torque
Settings Zinc Plated Fasteners and Dacromet
Fasteners Table 6. Torque Settings - Rivet Nut
Bolts/Screws
Bolt Size Bolt Size Nm kgf m lbf ft
ISO Metric Thread mm Nm kgf m lbf ft
M3 3 1.2 0.1 0.9
M4 4 3.0 0.3 2.0
M5 5 6.0 0.6 4.5
M6 6 10.0 1.0 7.5
M8 8 24.0 2.5 18.0
M10 10 48.0 4.9 35.5
M12 12 82.0 8.4 60.5
Table 7. Torque Settings - Internal Hexagon
Headed Cap Screws (Zinc)
Bolt Size Nm kgf m lbf ft
ISO Metric Thread Nm kgf m lbf ft
M3 2.0 0.2 1.5
M4 6.0 0.6 4.5
M5 11.0 1.1 8.0
M6 19.0 1.9 14.0
M8 46.0 4.7 34.0
M10 91.0 9.3 67.0
M12 159.0 16.2 117.0
M16 395.0 40.0 292.0
M18 550.0 56.0 406.0
M20 770.0 79.0 568.0
M24 1332.0 136.0 983.0
1-10
1-10
14
Section 1 - General Information Torque
Settings Hydraulic Connections Hydraulic
Connections T11-003 'O' Ring Face Seal
System Adaptors Screwed into Valve
Blocks Adaptor screwed into valve blocks, seal
onto an 'O' ring which is compressed into a 45
seat machined into the face of the tapped
port. Table 8. Torque Settings - BSP Adaptors
BSP Adaptor Size Hexagon (A/F) Nm kgf m lbf ft
in. mm Nm kgf m lbf ft
1/4 19.0 18.0 1.8 13.0
3/8 22.0 31.0 3.2 23.0
1/2 27.0 49.0 5.0 36.0
5/8 30.0 60.0 6.1 44.0
3/4 32.0 81.0 8.2 60.0
1 38.0 129.0 13.1 95.0
1 1/4 50.0 206.0 21.0 152.0
Table 9. Torque Settings - SAE Connections
SAE Tube Size SAE Port Thread Size Hexagon (A/F) Nm kgf m lbf ft
SAE Tube Size SAE Port Thread Size mm Nm kgf m lbf ft
4 7/16 - 20 15.9 20.0 - 28.0 2.0 - 2.8 16.5 - 18.5
6 9/16 - 18 19.1 46.0 - 54.0 4.7 - 5.5 34.0 - 40.0
8 3/4 - 16 22.2 95.0 - 105.0 9.7 - 10.7 69.0 - 77.0
10 7/8 - 14 27.0 130.0 - 140.0 13.2 - 14.3 96.0 - 104.0
12 1 1/16 - 12 31.8 190.0 - 210.0 19.4 - 21.4 141.0 - 155.0
16 1 5/16 - 12 38.1 290.0 - 310.0 29.6 - 31.6 216.0 - 230.0
20 1 5/8 47.6 280.0 - 380.0 28.5 - 38.7 210.0 - 280.0
1-11
1-10
15
Section 1 - General Information Torque
Settings Hydraulic Connections
Hoses Screwed into Adaptors
Fig 2.
Hoses 2-B screwed into adaptors 2-A seal onto an
O' ring 2-C which is compressed into a 45 seat
machined into the face of the adaptor port.
Note Dimension 2-D will vary depending upon the
torque applied.
Table 10. BSP Hose - Torque Settings
BSP Hose Size Hexagon (A/F) Nm kgf m lbf ft
in. mm Nm kgf m lbf ft
1/8 14.0 14.0 - 16.00 1.4 - 1.6 10.3 - 11.8
1/4 19.0 24.0 - 27.0 2.4 - 2.7 17.7 - 19.9
3/8 22.0 33.0 - 40.0 3.4 - 4.1 24.3 - 29.5
1/2 27.0 44.0 - 50.0 4.5 - 5.1 32.4 - 36.9
5/8 30.0 58.0 - 65.0 5.9 - 6.6 42.8 - 47.9
3/4 32.0 84.0 - 92.0 8.6 - 9.4 61.9 - 67.8
1 38.0 115.0 - 126.0 11.7 - 12.8 84.8 - 92.9
1 1/4 50.0 189.0 - 200.0 19.3 - 20.4 139.4 - 147.5
1 1/2 55.0 244.0 - 260.0 24.9 - 26.5 180.0 - 191.8
1-12
1-10
16
Section 1 - General Information Torque
Settings Hydraulic Connections Adaptors into
Component Connections with Bonded Washers Table
11. BSP Adaptors with Bonded Washers - Torque
Settings
BSP Size Nm kgf m lbf ft
in. Nm kgf m lbf ft
1/8 20.0 2.1 15.0
1/4 34.0 3.4 25.0
3/8 75.0 7.6 55.0
1/2 102.0 10.3 75.0
5/8 122.0 12.4 90.0
3/4 183.0 18.7 135.0
1 203.0 20.7 150.0
1 1/4 305.0 31.0 225.0
1 1/2 305.0 31.0 225.0
1-13
1-10
17
Section 1 - General Information Torque
Settings Hydraulic Connections
'Torque Stop' Hose System
Fig 3.
Torque Stop' Hoses 3-B screwed into adaptors 3-A
seal onto an 'O' ring 3-C which is compressed
into a 45 seat machined in the face of the
adaptor port. To prevent the 'O' ring being
damages as a result of over tightening, 'Torque
Stop' Hoses have an additional shoulder 3-D,
which acts as a physical stop.
Note Minimum dimension 3-E fixed by shoulder 3-D.
Table 12. BSP Torque Stop' Hose - Torque Settings
BSP Hose Size Hexagon (A/F) Nm kgf m lbf ft
in. mm Nm kgf m lbf ft
1/8 14.0 14.0 1.4 10.0
1/4 19.0 27.0 2.7 20.0
3/8 22.0 40.0 4.1 30.0
1/2 27.0 55.0 5.6 40.0
5/8 30.0 65.0 6.6 48.0
3/4 32.0 95.0 9.7 70.0
1 38.0 120.0 12.2 89.0
1 1/4 50.0 189.0 19.3 140.0
1 1/2 55.0 244.0 24.9 180.0
1-14
1-10
18
Section 2
Care and Safety
Service Manual - 1CX
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Maintenance
Section A - Attachments
Section B - Body and Framework
Section C - Electrics
Section E - Hydraulics
Section F - Transmission
Section G - Brakes
Section J - Tracks
Section K - Engine

Publication No. 9803/9960-3
World Class Customer Support
Copyright 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
Issued by JCB Technical Publications, JCB
Aftermarket Training, Woodseat, Rocester,
Staffordshire, ST14 5BW, England. Tel 44 1889
591300 Fax [phone]
19
Section 2 - Care and Safety
Contents Page No. Safety Notices Important
Information ......................................
..........................................
2-1 The Operator Manual ..........................
..................................................
2-1 Safety Warnings ..............................
..................................................
....2-1 Safety Check List ........................
..................................................
............. 2-2 Safety - Yours and Others
..................................................
...................2-2 General Safety
..................................................
....................................2-2 Operating
Safety ...........................................
........................................2-4 Mainte
nance Safety .....................................
..........................................2-7 Safe
ty Labels ........................................
..................................................
. 2-12 Introduction ..............................
..................................................
..........2-12
2-i
2-i
20
Section 2 - Care and Safety
Safety Notices Important Information T1-042
The Operator Manual
Safety Warnings
! WARNING
This safety alert system identifies important
safety messages in this manual. When you see
this symbol, be alert, your safety is involved,
carefully read the message that follows, and
inform other operators.
You and others can be killed or seriously injured
if you operate or maintain the machine without
first studying the Operator Manual. You must
understand and follow the instructions in the
Operator Manual. If you do not understand
anything, ask your employer or JCB dealer to
explain it.
In this publication and on the machine, there are
safety notices. Each notice starts with a signal
word. The signal word meanings are given below.
INT-1-4-2
Do not operate the machine without an Operator
Manual, or if there is anything on the machine
you do not understand.
! DANGER
Denotes an extreme hazard exists. If proper
precautions are not taken, it is highly probable
that the operator (or others) could be killed or
seriously injured.
Treat the Operator Manual as part of the machine.
Keep it clean and in good condition. Replace the
Operator Manual immediately if it is lost,
damaged or becomes unreadable.
INT-1-2-1
! WARNING Denotes a hazard exists. If proper
precautions are not taken, the operator (or
others) could be killed or seriously
injured. INT-1-2-2
! CAUTION
Denotes a reminder of safety practices. Failure
to follow these safety practices could result in
injury to the operator (or others) and possible
damage to the machine. INT-1-2-3
2-1
21
Section 2 - Care and Safety Safety Notices Safety
Check List Safety Check List P2-1005_3
Safety - Yours and Others
General Safety
INT-1-3-1_3 All machinery can be hazardous. When
a machine is correctly operated and properly
maintained, it is a safe machine to work with.
But when it is carelessly operated or poorly
maintained it can become a danger to you (the
operator) and others.
T1-043
! WARNING
To operate the machine safely you must
know the machine and have the skill to use it.
You must abide by all relevant laws, health
and safety regulations that apply to the
country you are operating in. The
Operator Manual instructs you on the
machine, its controls and its safe operation
it is not a training manual. If you are a new
operator, get yourself trained in the skills of
using a machine before trying to work with it.
If you don't, you will not do your job well, and
you will be a danger to yourself and others.
In this manual and on the machine you will find
warning messages. Read and understand them. They
tell you of potential hazards and how to avoid
them. If you do not fully understand the warning
messages, ask your employer or JCB distributor
to explain them.
But safety is not just a matter of responding to
the warnings. All the time you are working on or
with the machine you must be thinking what
hazards there might be and how to avoid them.
INT-1-4-1
! WARNING
Care and Alertness All the time you are working
with or on the machine, take care and stay
alert. Always be careful. Always be alert for
hazards.
Do not work with the machine until you are sure
that you can control it.
Do not start any job until you are sure that you
and those around you will be safe.
INT-1-3-5
! WARNING
If you are unsure of anything, about the machine
or the job, ask someone who knows. Do not assume
anything.
Clothing You can be injured if you do not wear
the proper clothing. Loose clothing can get
caught in the machinery. Wear protective
clothing to suit the job. Examples of protective
clothing are a hard hat, safety shoes, safety
glasses, a well fitting overall, ear- protectors
and industrial gloves. Keep cuffs fastened. Do
not wear a necktie or scarf. Keep long hair
restrained. Remove rings, watches and personal
jewellery.
Remember
BE CAREFUL BE ALERT BE SAFE
INT-1-3-6_2
! WARNING Alcohol and Drugs It is extremely
dangerous to operate machinery when under the
influence of alcohol or drugs. Do not consume
alcoholic drinks or take drugs before or while
operating the machine or attachments. Be aware
of medicines which can cause drowsiness. INT-1-3-9
_2
2-1
22
Section 2 - Care and Safety Safety Notices Safety
Check List
! WARNING
! DANGER
Feeling Unwell Do not attempt to operate the
machine if you are feeling unwell. By doing so
you could be a danger to yourself and those you
work with.
Lightning Lightning can kill you. Do not use the
machine if there is lightning in your area.
5-1-1-2
! WARNING Machine Modifications This machine
is manufactured in compliance with legislative
and other requirements. It should not be altered
in any way which could affect or invalidate any
of these requirements. For advice consult your
JCB Distributor.
8-1-2-4
! WARNING Mobile Phones Switch off your mobile
phone before entering an area with a potentially
explosive atmosphere. Sparks in such an area
could cause an explosion or fire resulting in
death or serious injury.
INT-1-3-10_2 Switch off and do not use your
mobile phone when refuelling the
machine. INT-3-3-9
! WARNING Lifting Equipment You can be injured if
you use incorrect or faulty lifting equipment.
You must identify the weight of the item to be
lifted then choose lifting equipment that is
strong enough and suitable for the job. Make
sure that lifting equipment is in good condition
and complies with all local regulations. INT-1-3-
7_2 ! WARNING Raised Equipment Never walk or work
under raised equipment unless it is supported by
a mechanical device. Equipment which is
supported only by a hydraulic device can drop
and injure you if the hydraulic system fails or
if the control is operated (even with the engine
stopped). Make sure that no-one goes near the
machine while you install or remove the
mechanical device. 13-2-3-7_3 ! WARNING Raised
Machine NEVER position yourself or any part of
your body under a raised machine which is not
properly supported. If the machine moves
unexpectedly you could become trapped and suffer
serious injury or be killed. INT-3-3-7_1
2-1
23
Section 2 - Care and Safety Safety Notices
Safety Check List ! WARNING
Operating Safety
! WARNING
Work Sites Work sites can be hazardous. Inspect
the site before working on it. You could be
killed or injured if the ground gives way under
your machine or if piled material collapses onto
it. Check for potholes and hidden debris, logs,
ironwork etc. Any of these could cause you to
lose control of your machine. Check for
utilities such as electric cables (overhead and
underground), gas and water pipes etc. Mark the
positions of the underground cables and pipes.
Make sure that you have enough clearance beneath
overhead cables and structures.
Machine Condition A defective machine can injure
you or others. Do not operate a machine which is
defective or has missing parts. Make sure the
maintenance procedures in this manual are
completed before using the machine.
INT-2-1-2_2
! WARNING
Machine Limits Operating the machine beyond its
design limits can damage the machine, it can
also be dangerous. Do not operate the machine
outside its limits. Do not try to upgrade the
machine performance with unapproved
modifications.
INT-2-2-1_2
! WARNING
Communications Bad communications can cause
accidents. Keep people around you informed of
what you will be doing. If you will be working
with other people, make sure any hand signals
that may be used are understood by everybody.
Work sites can be noisy, do not rely on spoken
commands.
INT-2-1-4
! WARNING
Engine/Steering Failure If the engine or steering
fails, stop the machine as quickly as possible.
Do not operate the machine until the fault has
been corrected.
INT-2-2-3
! WARNING
INT-2-1-5
! WARNING
Parking An incorrectly parked machine can move
without an operator. Follow the instructions in
the Operator Manual to park the machine
correctly.
Exhaust Gases Breathing the machine exhaust gases
can harm and possibly kill you. Do not operate
the machine in closed spaces without making sure
there is good ventilation. If possible, fit an
exhaust extension. If you begin to feel drowsy,
stop the machine at once and get into fresh air.
INT-2-2-4_2
! WARNING
Banks and Trenches Banked material and trenches
can collapse. Do not work or drive too close to
banks and trenches where there is danger of
collapse.
INT-2-1-10_2
INT-2-2-5
! WARNING Safety Barriers Unguarded machines in
public places can be dangerous. In public
places, or where your visibility is reduced,
place barriers around the work area to keep
people away. INT-2-2-8
2-1
24
Section 2 - Care and Safety Safety Notices Safety
Check List
! DANGER
! WARNING
Sparks Explosions and fire can be caused by
sparks from the exhaust or the electrical
system. Do not use the machine in closed areas
where there is flammable material, vapour or
dust.
Keep the machine controls clean and dry. Your
hands and feet could slide off slippery
controls. If that happens you could lose control
of the machine.
2-2-3-6
! WARNING
INT-2-2-10
! WARNING
Electrical Power Cables You could be electrocuted
or badly burned if you get the machine or its
attachments too close to electrical power cables.
Hazardous Atmospheres This machine is designed
for use in normal out door atmospheric
conditions. It should not be used in an enclosed
area without adequate ventilation. Do not use
the machine in a potentially explosive
atmosphere, i.e. combustible vapours, gas or
dust, without first consulting your JCB
Distributor.
You are strongly advised to make sure that the
safety arrangements on site comply with the
local laws and regulations concerning work near
electric power lines.
Before you start using the machine, check with
your electricity supplier if there are any
buried power cables on the site.
INT-2-1-14
! CAUTION
There is a minimum clearance required for working
beneath overhead power cables. You must obtain
details from your local electricity supplier.
Regulations Obey all laws, work site and local
regulations which affect you and your machine.
INT-1-3-3
2-2-5-4
! CAUTION
! WARNING
Practise You or others can be killed or seriously
injured if you do unfamiliar operations without
first practising them. Practise away from the
work site on a clear area. Keep other people
away. Do not perform new operations until you
are sure you can do them safely.
If you have an attachment which is not covered in
the Operator Manual do not install it, use it or
remove it until you have obtained, read and
understood the pertinent information. Install
attachments only on the machines for which they
were designed.
5-5-1-1_2
! WARNING Use only the JCB approved
attachments that are specified for your machine.
Operating with non- specified attachments can
overload the machine, causing possible damage
and machine instability which could result in
injury to yourself or others.
INT-2-1-1
! WARNING Airborne particles of light
combustible material such as straw, grass, wood
shavings, etc. must not be allowed to accumulate
within the engine compartment or in the
propshaft guards (when fitted). Inspect these
areas frequently and clean at the beginning of
each work shift or more often if required.
Before opening the engine cover, ensure that the
top is clear of debris.
The use of non-approved attachments could
invalidate your warranty.
2-4-5-2_1
5-3-1-12_3
2-1
25
Section 2 - Care and Safety Safety Notices Safety
Check List
! DANGER
! WARNING
Working Platform Using the machine as a working
platform is hazardous you can fall off and be
killed or injured. Never use the machine as a
working platform.
High Loads A high load can block your view and
reduce the machine's stability. Travel with the
load low to the ground. Travel slowly and with
caution over rough, muddy or loose surfaces.
5-1-5-9
! WARNING Machine Safety Stop work at once if
a fault develops. Abnormal sounds and smells can
be signs of trouble. Inspect and repair before
resuming work.
5-1-3-2
! WARNING Slopes When transporting a load on a
slope, drive slowly and keep the load uphill of
the machine. This will increase stability.
8-1-2-3
! WARNING Touching hot surfaces can burn skin.
The engine and machine components will be hot
after the unit has been running. Allow the
engine and components to cool before servicing
the unit.
5-1-4-1
! WARNING Hillsides Operating the machine on
hillsides can be dangerous if proper precautions
are not taken. Ground conditions can be changed
by rain, snow, ice etc. Check the site
carefully. Operate in first gear on hillsides,
when applicable, keep all attachments low to the
ground. Never coast down a hill with the engine
off or the transmission in neutral.
10-1-1-40
! WARNING
Travelling at High Speeds Travelling at high
speeds can cause accidents. Do not reverse in a
high gear with full throttle. Always travel at a
safe speed to suit working conditions.
INT-2-2-7
! WARNING
INT-5-3-3
Visibility Accidents can be caused by working in
poor visibility. Use your lights to improve
visibility. Keep the road lights, windows and
mirrors clean.
! WARNING
The engine has exposed rotating parts. Switch OFF
the engine before working in the engine
compartment. Do not use the machine with the
engine cover open.
Do not operate the machine if you cannot see
clearly.
5-1-4-7
5-2-6-5
! WARNING
! WARNING
Keep Your Hands and Feet Inside the Vehicle When
using the machine, keep your hands and feet
clear of moving parts. Keep your hands and feet
within the operator compartment while the
vehicle is in motion.
You could be killed or seriously injured if you
operate a machine with a damaged or missing
ROPS/FOPS. If the Roll Over Protection Structure
(ROPS)/Falling Objects Protection Structure
(FOPS) has been in an accident, do not use the
machine until the structure has been renewed.
Modifications and repairs that are not approved
by the manufacturer may be dangerous and will
invalidate the ROPS/FOPS certification.
13-1-1-17
INT-2-1-9_6
2-1
26
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Section 2 - Care and Safety Safety Notices Safety
Check List
! WARNING
Maintenance Safety
Controls You or others can be killed or seriously
injured if you operate the control levers from
outside the machine. Operate the control levers
only when you are correctly seated.
! WARNING
Communications Bad communications can cause
accidents. If two or more people are working on
the machine, make sure each is aware of what the
others are doing. Before starting the engine
make sure the others are clear of the danger
areas examples of danger areas are the
rotating blades and belt on the engine, the
attachments and linkages, and anywhere beneath or
behind the machine. People can be killed or
injured if these precautions are not taken.
0179_2
! CAUTION
Passengers Passengers in or on the machine can
cause accidents. Do not carry passengers.
INT-2-2-2_1
INT-3-1-5
! WARNING
! WARNING
Fires If your machine is equipped with a fire
extinguisher, make sure it is checked regularly.
Keep it in the correct machine location until
you need to use it.
Repairs If your machine does not function
correctly in any way, get it repaired straight
away. Neglect of necessary repairs could result
in an accident or affect your health. Do not try
to do repairs or any other type of maintenance
work you do not understand. To avoid injury
and/or damage get the work done by a specialist
engineer.
Do not use water to put out a machine fire, you
could spread an oil fire or get a shock from an
electrical fire. Use carbon dioxide, dry
chemical or foam extinguishers. Contact your
nearest fire department as quickly as possible.
Firefighters should use self- contained
breathing apparatus.
GEN-1-5_2
! WARNING
INT-3-2-7_2
Metal Splinters You can be injured by flying
metal splinters when driving metal pins in or
out. Use a soft faced hammer or copper pin to
remove and fit metal pins. Always wear safety
glasses.
! WARNING
Should the machine start to roll over, you can be
crushed if you try to leave the cab. If the
machine starts to roll over, do not try and jump
from the cab. Stay in the cab, with your seat
belt fastened.
INT-3-1-3_2
! WARNING
INT-2-1-12
Electrical Circuits Understand the electrical
circuit before connecting or disconnecting an
electrical component. A wrong connection can
cause injury and/or damage. INT-3-1-4
2-7
2-7
9803/9960-3
28
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